US11702843B2 - Coated panel and method for manufacturing a coated panel - Google Patents

Coated panel and method for manufacturing a coated panel Download PDF

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US11702843B2
US11702843B2 US16/326,494 US201616326494A US11702843B2 US 11702843 B2 US11702843 B2 US 11702843B2 US 201616326494 A US201616326494 A US 201616326494A US 11702843 B2 US11702843 B2 US 11702843B2
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oligomer
carrier plate
panel
amount
onto
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US20210285226A1 (en
Inventor
Dieter Döhring
Manfred Biehler
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Lignum Technologies AG
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Xylo Technologies AG
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0866—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/30—Processes for applying liquids or other fluent materials performed by gravity only, i.e. flow coating
    • B05D1/305—Curtain coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/56—Three layers or more
    • B05D7/58—No clear coat specified
    • B05D7/582—No clear coat specified all layers being cured or baked together
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/067—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C13/00—Fibre or filament compositions
    • C03C13/06—Mineral fibres, e.g. slag wool, mineral wool, rock wool
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/26—Macromolecular compounds or prepolymers
    • C03C25/32—Macromolecular compounds or prepolymers obtained otherwise than by reactions involving only carbon-to-carbon unsaturated bonds
    • C03C25/326—Polyureas; Polyurethanes
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/48—Coating with two or more coatings having different compositions
    • C03C25/50—Coatings containing organic materials only
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
    • C04B41/61—Coating or impregnation
    • C04B41/70—Coating or impregnation for obtaining at least two superposed coatings having different compositions
    • C04B41/71—Coating or impregnation for obtaining at least two superposed coatings having different compositions at least one coating being an organic material
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D175/00—Coating compositions based on polyureas or polyurethanes; Coating compositions based on derivatives of such polymers
    • C09D175/04—Polyurethanes
    • C09D175/14—Polyurethanes having carbon-to-carbon unsaturated bonds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/002—Priming paints
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/0889—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
    • E04F13/0894—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections with tongue and groove connections
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02177—Floor elements for use at a specific location
    • E04F15/02183—Floor elements for use at a specific location for outdoor use, e.g. in decks, patios, terraces, verandas or the like
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C2213/00—Glass fibres or filaments
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/04—Other details of tongues or grooves
    • E04F2201/043—Other details of tongues or grooves with tongues and grooves being formed by projecting or recessed parts of the panel layers

Definitions

  • the present invention relates to a coated panel and a method for manufacturing a coated panel, in particular a wall, ceiling or floor panel, having a carrier plate of mineral wool or glass wool.
  • Laminate panels are relatively inexpensive and easy to handle.
  • they comprise a carrier plate made from medium density fiberboard (MDF) or high density fiberboard (HDF) material, whereby on the top side thereof a decor paper impregnated with a melamine resin is applied.
  • MDF medium density fiberboard
  • HDF high density fiberboard
  • the resin is cured, so that a highly abrasion resistant surface is created.
  • abrasion resistant particles are applied onto the surface before the pressing step, in particular particles of corundum.
  • One disadvantage of such laminate panels is that they are hardly suitable for applications in outdoor areas, where they are subjected to weather conditions and moisture, for which they are typically not suitable.
  • high-quality panels based on PVC are known, which are marketed under the name LVT (Lacquered Vinyl Tile). These are made by gluing a decor paper onto a soft PVC layer, respectively plate, to provide the visible surface of the PVC with the desired decor.
  • LVT Lacquered Vinyl Tile
  • plastic foils As alternative for decor papers also the use of plastic foils is known, which likewise can, for example, be provided with a decorative decor.
  • these PVC-based panels are hardly suitable for applications in outdoor areas, where they are subjected to UV radiation and moisture.
  • the carrier plate consists of MDF or HDF made from acetylated wood, of a fiber cement plate or a preferably particularly treated PVC panel.
  • the present invention is directed to the task to improve the known prior art and to provide in particular an improved panel and method for the manufacturing thereof, whereby the panel is particularly suitable for applications in outdoor areas.
  • the new panels on the basis of a carrier plate of mineral wool or glass wool should have a good stability compared to known materials when used in outdoor areas and delete the disadvantage of the high alkalinity of fiber cement panels.
  • a method for manufacturing of a coated panel is provided, in particular of a wall, ceiling or flooring panel for outdoor areas.
  • a carrier plate of mineral wool or glass wool is provided, which comprises a front side (major front surface) and a rear side (major rear surface).
  • the carrier plate is preferably relatively rigid to facilitate the mounting of such panels to achieve a wall, ceiling or floor covering. It can be treated on its front and rear side, and/or provided with additional functional layers to, for example, improve its resistance against harsh environmental conditions.
  • a primer is applied onto the front side of the carrier plate. The primer serves to improve the adhesion of the subsequently applied layers onto the front side of the carrier plate.
  • the primer is in particular important for applications in outdoor areas: it has to be chosen such that it forms a durable barrier layer to prevent that water absorbed by the carrier plate can reach the additional layers applied on top of the primer layer. If that is not the case, there is a risk that e.g. upon repeatedly freezing the additional layers separate from the carrier plate.
  • the primer comprises isocyanate or is based on isocyanate.
  • the primer is applied in an amount of 3 to 300 g/m 2 , more preferred 15 to 150 g/m 2 and particularly preferred 30 to 80 g/m 2 .
  • the application can be done by means of a roll applicator.
  • the primer penetrates upon application into the surface of the fiber plate. Even if the isocyanate needs some time to form a polyurethane with water, the next application steps can follow immediately.
  • additional base coat layers are applied onto the primer.
  • These base coat layers can, for example, be applied as filler layers with suitable roll applicators directly onto the primer and cured by means of elevated temperatures or by means of UV radiation.
  • the filler layers are applied preferably in an amount of 0 to 150 g/m 2 , more preferably 10 to 100 g/m 2 and most preferably 12 to 40 g/m 2 .
  • a printing base coat is applied by means of roll applicators or by means of curtain coating (and in particular preferably onto the base coat layer), whereby the drying or curing is again achieved by means of elevated temperature or UV radiation.
  • the amount of printing base coat applied is preferably in the range of 0 to 100 g/m 2 , more preferred between 15 and 90 g/m 2 .
  • the surface may be printed with a decor, as for example a wood or stone imitation.
  • the print can be achieved with any kind of suitable printing method, however, preferably by means of digital printing with water-based or UV-curable inks.
  • a first oligomer 1A is applied in an amount of 30 to 150 g/m 2 .
  • the oligomer 1A is preferably liquid and it is e.g. applied by means of a suitable roll application method or by pouring or spraying.
  • a second oligomer which may differ chemically from the first oligomer, is applied in an amount of 30 to 180 g/m 2 onto the still wet surface of the prior applied layer of the first oligomer 1A. This is done preferably by a curtain coating method or by spraying.
  • the second oligomer can also be applied firstly onto a transfer foil, and this foil is supplied to the still wet surface of the first oligomer layer, i.e.
  • the two applied wet oligomers are cured together, for example by using a suitable radiation which is radiated through the foil and by subsequently removing the foil again. If no transfer foil is used, curing should occur preferably under inert conditions, i.e. under exclusion of oxygen.
  • the transfer foil provides such oxygen exclusion.
  • first oligomer 1A and second oligomer also multiple oligomer layers may be applied to further increase the durability.
  • first oligomer 1A is slightly gelled by means of radiation and thus fixed onto the plate.
  • another layer of the first oligomer 1A or of a modified first oligomer 1B may be applied. It is decisive that the respective topmost layer remains wet and that the second oligomer is applied wet as well, and that finally all these layers are polymerized together.
  • the step of application of the first oligomer 1A is done in at least two partial steps.
  • the first oligomer 1A is supplied in an amount of 30 to 100 g/m 2 (more preferred of 35 to 90 g/m 2 ) in liquid form and this layer is subsequently slightly gelled.
  • “slightly gel” means in this connection that the oligomer is not fully cured, but only to a small part. Slightly gelling should preferably solidify the applied oligomer to such an extent that it is possible to apply in a second partial step a further application of the first oligomer 1A or a modified oligomer 1B by means of roll applicators.
  • roll applicators are not particularly suitable for a wet-on-wet application of different oligomers, since at the second roll a mixture of the oligomers can occur, which can be disadvantageous.
  • slightly gelling the first oligomer applied in the first partial step such a mixture or contamination at the second roll can be prevented.
  • 10 to 90 g/m 2 of the first oligomer 1A or a modified oligomer 1B is applied onto the slightly gelled surface, i.e. preferably in an amount that the desired end amount of 30 to 180 g/m 2 is achieved.
  • the second oligomer is applied in liquid form.
  • the application is preferably done by curtain coating, spraying or by means of a transfer foil.
  • a mixture of the two topmost oligomer layers of the first and second oligomers occurs at least in the border region. It is advantageous that the thus coated material is polymerized under inert conditions, for example under exclusion of oxygen, since thereby a high double bond conversion and thus a good interlinking is achieved.
  • the mechanical properties of the coating can be precisely adjusted, as it is for example necessary with highly loaded floorings in outdoor areas.
  • the uppermost surface needs to be hard and scratch-proof to withstand the load. This can for example be achieved by a high degree of interlinking.
  • the first oligomers 1A and respectively also 1B are chosen advantageously with a lower interlinking potential.
  • the first oligomer 1A/B is based on one or more of the following materials:
  • Suitable polyurethane acrylates are in particular urethane-group-containing compounds, which comprise in average 2 to 10, in particular 2 to 8.5 acrylate or methacrylate groups and which are preferably derivable by reacting of aromatic or aliphatic di- or oligo-isocyanates with hydroxyalkyl-acrylates or hydroxyalkyl-methacrylates.
  • Examples for these compounds are the Laromer® types, UA19T, UA9028, UA9030, LR8987, UA9029, UA9033, UA9047, UA9048, UA9050, UA9072 of the company BASF SE, whereby some of those are mixtures of monomers.
  • oligomer 1A can also use oligomer 1A, but one can also use a modified first oligomer 1B, which consists essentially of the same chemical compounds described for the first oligomer 1A, whereby, however, the molar relationship of these compounds is preferably modified (i.e. the mixture of the chemical compounds is modified), so that different mechanical properties, as in particular a slightly increased hardness in this layer can be achieved.
  • a modified first oligomer 1B which consists essentially of the same chemical compounds described for the first oligomer 1A, whereby, however, the molar relationship of these compounds is preferably modified (i.e. the mixture of the chemical compounds is modified), so that different mechanical properties, as in particular a slightly increased hardness in this layer can be achieved.
  • the second oligomer can be based on the same chemical compounds as the first oligomer 1A, 1B, however, the composition should preferably be chosen such that the upper respectively topmost layer can achieve a significantly higher cross-linking.
  • the amount of cross-linking and thus also the hardness can for example be influenced by the amount of Laromer HDDA (hexanediol diacrylate) of the company BASF.
  • HDDA consists of small molecules that lead to a higher cross-linking: i.e. when increasing the amount of HDDA also the cross-linking and thus the resulting hardness is increased. It is also possible to use polyester or polyether structures, however, the weather resistance is degraded thereby.
  • the weather resistance of the above-described oligomers 1A, 1B and 2 can, aside from a choice of suitable oligomers and monomers, also be improved by using UV absorbers and sterically hindered amines.
  • Suitable stabilizers comprise typical UV absorbers as oxanilides, triacines and benzotriazol (e.g. derivable as Tinuvin® by the company BASF SE) and benzophenone.
  • radical interceptors as for example sterically hindered amines as 2,2,6,6-tetramethylpiperidine, 2,6-di-tert-butylpiperidine or derivates therefrom, as for example bis-(2,2,6,6-tetra-methyl-4-piperidyl)sebacinat.
  • Stabilizers are typically used in amounts of 0.5 to 5 weight percent in relation to the “solid” compounds in the mixture.
  • Oligomer 1 can be made in the following composition, whereby the chemical compounds can in principle also be used for oligomer 2 (but in a different relative mixture):
  • the inventive composition comprises at least one photo initiator.
  • Photo initiators are substances, which decompose due to irradiation with UV radiation, i.e. with a wavelength below 420 nm, and in particular below 400 nm, by forming radicals and thereby triggering a polymerization of the ethylenitically unsaturated double bonds.
  • the radiation-curable, liquid composition comprises at least one photo initiator, which has an absorption band that comprises a maximum in the range of 220 to 420 nm, in particular in the range of 240 to 400 nm.
  • the non-watery, liquid, radiation-curable composition comprises at least one photo initiator, which has an absorption band with a maximum in the range of 220 to 420 nm, in particular a maximum in the range of 240 to 420 nm and particularly a maximum in the range of 340 to 420 nm.
  • photo initiators with an absorption maximum in the short wave UV range would be completely absorbed by the UV absorbers and therefore not sufficiently initiate the polymerization.
  • Photo initiators can for example be chosen from photo initiators known by the skilled person, as for example described in “Advances in Polymer Science”, Volume 14, Springer Berlin 1974 or in K. K. Dietliker, Chemistry and Technology of UV- and EB-Formulation for Coatings, Inks and Paints, Volume 3; Photoinitiators for Free Radical and Cationic Polymerization, P. K. T. Oldring (Eds), SITA Technology Ltd, London.
  • Suitable are for example mono- or bi-sacylphosphinoxide, as for example mentioned in EP-A 7 508, EP-A 57 474, DE-A 196 18 720, EP-A 495 751 or EP-A 615 980, as for example 2,4,6-Trimethylbenzoyldiphenylphosphinoxide (Irgacure® TPO of the company BASF SE), Ethyl-2,4,6-trimethylbenzoylphenylphosphinat (Irgacure® TPO L der BASF SE), Bis-(2,4,6-trimethylbenzoyl)-phenyl phosphine oxide (Irgacure® 819 der Firma BASF SE), benzophenone, hydroxyacetophenone, phenylglyoxyl acid and its derivates or mixtures of these photo initiators.
  • Irgacure® TPO of the company BASF SE
  • Examples are: benzophenone, aceto-phenone, aceto-naphthoquinone, methyl ethyl ketone, ⁇ -phenyl-butyrophenone, p-morpholino-propiophenone, 4-morpholino-benzophenone, 4-morpholino-deoxybenzoine, p-diacetylbenzene, 4-amino-benzophenone, 4′-methoxy-acetophenone, ⁇ -methyl-anthraquinon, tert-butyl-anthraquinon, anthraquinone-carboxyl acid, benzaldehyd, ⁇ -Tetralon, 9-acetyl-phenanthrene, 2-ace-tyl-phenanthren, 10-thioxanthen, 3-acetyl-phenanthrene, 3-acetyl-indole, 9-fluorenone, 1-indanone, 1,3,4-triacetyl-benz
  • photo initiators are polymeric photo initiators, as for example the di-ester of carboxylmethoxybenzophenone with polytetramethylen glycoles of different molar weights, preferably 200 to 250 g/mol (CAS 515136-48-8), as well as CAS 1246194-73-9, CAS 813452-37-8, CAS 71512-90-8, CAS 886463-10-1 or further polymeric benzophenone derivative, as for example known under the trade name Omnipol® BP of the company Rahn AG, Switzerland.
  • polymeric photo initiators as for example the di-ester of carboxylmethoxybenzophenone with polytetramethylen glycoles of different molar weights, preferably 200 to 250 g/mol (CAS 515136-48-8), as well as CAS 1246194-73-9, CAS 813452-37-8, CAS 71512-90-8, CAS 886463-10-1 or further polymeric benzophenone derivative, as for example known under the trade name Omnipol®
  • silsesquioxane compounds with at least one initiating group as described in WO 2010/063612 A1, in particular on page 2, line 21 to page 43, line 9, preferably from page 2, line 21 to page 30, line 5 as well as in the examples of the WO 2010/063612 A1 mentioned compounds (all herewith incorporated by reference).
  • Typical mixtures comprise for example: 2-hydroxy-2-methyl-1-phenyl-propane-2-one and 1-hydroxy-cyclohexyl-phenylketone, bis(2,6-dimethoxybenzyl)-2,4,4-trimethylpentylphosphine oxide and 2-hydroxy-2-methyl-1-phenyl-propane-1-one, benzophenone and 1-hydroxy-cyclohexyl-phenylketone, bis(2,6-dimethoxybenzyl)-2,4,4-trimethylpentylphosphine oxide and 1-hydroxy-cyclohexyl-phenylketone, 2,4,6-trimethylbenzyldiphenyl-phosphine oxide and 2-hydroxy-2-methyl-1-phenyl-propane-1-one, 2,4,6-trimethylbenzophenone and 4-methylbenzophenone or 2,4,6-trimethylbenzophenone and 4-methylbenzophenone and 2,4,6-trimethylbenzyldiphenylphosphine oxide.
  • photo initiators are: 2,4,6-trimethylbenzyldiphenylphosphine oxide, ethyl-2,4,6-trimethylbenzylphenyl-phosphinate, bis-(2,4,6-trimethylbenzoyl)-phenylphosphine oxide, benzophenone, 1-benzylcyclohexan-1-ol, 2-hydroxy-2,2-di-methylacetophenone and 2,2-dimethoxy-2-phenylacetophenone.
  • inventive, liquid, radiation-curable compounds can also be formed initiato-free, in particular if the subsequent curing is achieved by electron beams.
  • a primer on the basis of an isocyanate is used:
  • the poly-isocyanate compound is preferably an aliphatic or cyclo-aliphatic compound, di- and poly-isocyanates with an NCO functionality of at least 1.8, preferably 1.8 to 5 and particularly preferred 2 to 4 and/or isocyanurates, biurates, allophanates and uretdiones thereof, which can be achieved from the base di-isocyanates in monomer form by oligomerization.
  • a disadvantage of the use of such an isocyanate compound is that the layer remains liquid and can hardly be solidified in the ongoing manufacturing process, since the curing process takes several hours. Nevertheless, it was surprisingly found that it is possible to apply onto this wet layer additional layers of filler material and printing base coat as described above. That means that the isocyanate primer can be applied in the production line without any disturbances and the following layers can be applied directly thereon. Although the mechanisms are not fully understood, it is assumed that this is due to the porous structure of the carrier plate, which allows a good fixation of the still wet primer.
  • the isocyanate compound can be mixed with an acrylate compound.
  • the advantage is that the acrylate compound can be fixed (slightly gelled) by means of radiation, whereby the isocyanate compound is likewise fixed.
  • the chemical cross-linking by means of a poly-addition reaction of the isocyanates is completed over several hours. The final strength of the whole coating is reached typically after about 48 hours.
  • the relation of isocyanate compound to acrylate compound should be chosen suitable. The best strength is in principle achieved if only isocyanate is used. The higher the amount of acrylate compound is, the less the resistivity of the flooring will be. A relationship of above 50% of an acrylate compound is therefore not suitable.
  • the acrylate compound is at least a mono-functional alkyl methacrylate, which comprises as a glass transition temperature of not more than 0° C.
  • alkyl methacrylate in the form of meth acryl acid ester of alkanols, which have 2 to 12 carbon atoms, is used.
  • the alkyl methacrylate have a boiling point at normal pressure of at least 140° C., in particular of at least 200° C. This leads to a low volatility of the alkyl methacrylate.
  • the compound is chosen from the group consisting of: ethyl acrylate, propyl acrylate, iso-propyl acrylate, n-Butyl acrylate, n-hexyl acrylate, n-octyl acrylate, 2-ethyl hexyl acrylate, 3-propyl heptyl acrylate, n-decyl acrylate, lauryl acrylate, n-pentyl methacrylate, n-octyl methacrylate, n-decyl methacrylate und lauryl methacrylate, butyl methacrylate, 2-ethylhexyl-acrylate or 3-propyl heptyl acrylate.
  • the flooring panel manufactured this way comprises preferably the following properties. Since such a panel is a complex product, which is made of an essentially non-organic mineral wool carrier plate and a polymeric coating, the different parts are separated as follows and described separately: 1. mineral wool or glass wool carrier plate and 2. the applied coating, which is mechanically separated from the carrier plate.
  • the carrier plate comprises preferably the following parameters: tensile strength, according to DIN EN310 of 15 to 50 N/m 2 , more preferred 20 to 40 N/m 2 and most preferred 25 to 40 N/m 2 .
  • the young's module derived by the same method is preferably 3500 to 6000 N/m 2 , more preferred 4000 to 6000 N/m 2 .
  • the stated parameters apply for temperatures between ⁇ 20° C. and +70° C.
  • the mechanically separated, cured oligomer coating comprises preferably the following mechanical properties:
  • the tensile strength as derived, for example, from the test methods described in DIN EN ISO 527-1 and DIN EN ISO 527-2 is in the range of 3 to 30 N/mm 2 , more preferred 5 to 20 N/mm 2 , and even more preferred 6 to 18 N/mm 2 .
  • the corresponding young's modulus (also known as the elastic modulus) is preferably in the range of 400 to 3000 N/mm 2 , more preferred 600 to 2500 N/mm 2 and even more preferred 800 to 2000 N/mm 2 .
  • the above-mentioned values apply for temperatures between ⁇ 20° C. and +70° C.
  • the carrier plate is provided on its side with coupling means in the form of tongue and groove elements that allow connection of several identical panels in directions parallel to the front side as well as perpendicular to the front side by means of a form fitting connection.
  • the printing is done by means of direct printing with a digital printer.
  • the major front surface of the carrier plate is in particular pre-treated before the printing, and in particular grinded and subsequently provided with a base coating.
  • the subsequently applied oligomer layers are preferably essentially transparent, so that the printed decor is visible in the final product.
  • the carrier plate has preferably a thickness between 3 and 20 mm, more preferred between 4 and 15 mm, even more preferred between 3 and 12 mm and most preferred between 4 and 10 mm.
  • FIGS. 1 and 2 show exemplary layer arrangements in a schematic illustration
  • FIG. 3 shows an exemplary facility for manufacturing an inventive panel in a schematic illustration.
  • FIG. 1 a schematic layer structure for a panel 1 according to the invention is shown.
  • the carrier plate 10 is substantially thicker than the further layers 4 , 12 , 13 and 14 , which are, for example, in the range of several hundred ⁇ m.
  • the panel 1 can in addition comprise further layers, as in particular base coatings, a decor layer as well as eventually a primer layer for the decor layer and others.
  • the carrier plate 10 is provided with a thickness of approximately 8 mm and is made from mineral wool.
  • a moisture barrier 4 in the form of a suitable plastic foil is applied.
  • the moisture barrier is optional and depends on the material for the carrier plate 10 and the intended use.
  • the carrier plate 10 further comprises coupling means in the form of groove 3 , respectively tongue elements 2 , which are only sketched in the figures.
  • Suitable coupling means in the form of groove and tongue elements that allow a connection of several identical panels in directions parallel to the major front surface as well as perpendicular to the major front surface by means of form fitting are known to the skilled person, for example from the field of laminate floorings. It is referred for the details of such coupling means exemplarily to WO 0188306 or WO 0148332 of the same applicant, which contents are herewith incorporated by reference.
  • a primer 12 was applied onto the major front surface of carrier plate 10 .
  • a first layer of the liquid oligomer 13 was applied in an amount of 30 to 150 g/m 2 .
  • a second layer 14 of a second oligomer is arranged, which is different from the first oligomer.
  • this second layer 14 was applied in an amount of 30 to 150 g/m 2 .
  • Both layers 13 and 14 were applied wet on wet, so that at the border surface between both layers the two liquid base materials were partially mixed. The composition in this border region of both layers 13 and 14 is thus different to the composition of the base materials of layers 13 and 14 .
  • a modified panel 1 ′ is shown, wherein in contrast to panel 1 the application of the layer of the first oligomer is done in two partial steps.
  • a first layer 13 . 1 is applied in an amount of 30 to 100 g/m 2 .
  • This applied substance was slightly gelled and after that in a second partial step, the rest of the first oligomer was applied as layer 13 . 2 onto the slightly gelled (not fully cured) surface of layer 13 . 1 . Therefore, no mixture occurs between both layers 13 . 1 and 13 . 2 .
  • a second oligomer was applied onto the still wet layer 13 . 2 in the form of layer 14 .
  • the whole layer system is preferably fully cured by means of radiation.
  • FIG. 3 shows schematic a facility for the coating of carrier plates 10 .
  • the carrier plates are further processed after the coating in a separate cutting line (not shown) and provided with coupling means, i.e. with a suitable coupling profile, in particular with groove and tongue elements.
  • the carrier plates 10 are based on mineral wool and have, for example, a thickness between 3 and 20 mm, a length (as seen in the transport direction of the facility of FIG. 3 ) of 150 to 200 cm and a width of 125 to 210 cm. However, also other dimensions for the carrier plates can be used, which are then cut into the desired form and shape at the end of the process.
  • additional processing stations may be provided, as in particular additional drying stations, stations for the application of primers, stations for the application of base coatings, control and monitoring devices, printing devices for application of a decor, etc.
  • the carrier plates 10 are transported through the coating facility by means of roll conveyors 31 .
  • a primer 12 is applied by means of a liquid curtain onto the major front surface of the carrier plates 10 .
  • the liquid curtain of the primer extends over the whole width of the plates and the plates are transported through this curtain and thereby coated with the primer.
  • a container 23 is arranged, into which the liquid curtain falls, when no plate is transported through the curtain, as it, for example, occurs with the gaps between two successive plates.
  • step 33 the primer is dried, for example by means of hot air.
  • a first layer 13 of a first oligomer is applied in an amount of 30 to 150 g/m 2 onto the major front surface of carrier plate 10 .
  • the carrier plate is thereafter transported with the layer 13 of the first oligomer without any subsequent drying or curing.
  • an additional layer 14 of a liquid, second oligomer is applied onto the still wet surface of layer 13 of the first oligomer by means of, for example, a curtain coating.
  • the second oligomer differs from the first oligomer and is likewise applied in an amount of 30 to 150 g/m 2 .
  • the layers of the still wet oligomers are cured, preferably by means of radiation.

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US20220307274A1 (en) * 2021-03-24 2022-09-29 John J. Kunzler Flooring panels with slidable edge joints
CN114370136B (zh) * 2022-01-26 2024-01-30 中建八局装饰工程有限公司 一种聚酯纤维板装配式硬包施工工艺

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RU2712992C1 (ru) 2020-02-03
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US20210285226A1 (en) 2021-09-16
EP3500535A1 (en) 2019-06-26
CA3033081C (en) 2023-12-05
CA3033081A1 (en) 2018-02-22
CN109843825A (zh) 2019-06-04
PL3500535T3 (pl) 2020-12-14
HUE050254T2 (hu) 2020-11-30
UA122543C2 (uk) 2020-11-25
PT3500535T (pt) 2020-09-01
DK3500535T3 (da) 2020-08-24
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EP3620443A1 (en) 2020-03-11
ES2812778T3 (es) 2021-03-18

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